Wiring nightmare

[David99]

Hello all, I recently picked up a 1982 XS650 Heritage and it wasn't until I got it home that I realized what bad shape the wiring was in. Somebody had some fun. The headlight and tail light don't work. One turn signal indicator is out, the left rear turn signal is out. ...etc. but hey, the horn works!
Any tips on how to proceed with something like this? I have the manual and found the wiring diagram, but holy macaroli! The wires have been altered, so the color coding is out the window. I'm in over my head. I would like to attempt a fix, but it seems like a challenge.
Any help would be appreciated!

 

[Its been a long time]

Take it one circuit at a time. Personally, if I found a non standard wire colour, I would replace it with the correct colour wire. It's far better for future troubleshooting for the loom to be standard colours.

It's not so daunting if you take it one circuit at a time. Trying to look at the entire system can be a daunting prospect. So don't do it like that. Hope that helps.

 

[JJames]

I'm no expert, but as IBALT says, one circuit at a time. Make sure your grounds are clean and solid and trace the wires out from the fuse box, witch, if it has one should be replaced or converted to blade style fuses. Welcome to the forum. Have fun.

 

[Its been a long time]

Yes IIRC an 82 has four fuses in a fuse box that deteriorates with age. Replace with a suitable blade type fuse holder as recommended above.

 

[willis]

Depending on how bad it is, you could always buy a new harness from Mikes for $100. There have been good reports on the quality of their wiring harnesses.

https://www.mikesxs.net/yamaha-xs65...?fits-motorcycle=Yamaha/XS650/all-models/1982

 

[jetmechmarty]

Why not just buy a replacement harness and be done with it?

https://www.mikesxs.net/yamaha-xs650-wire-loom-82-84-sj-sk-sl-5v4-82590-oem-5v4-82590-50-00.html

 

[Niels B]

Yes replace the harness, it’s surprisingly cheap and easy to do as well, you’ll eliminate bad/corroded connections as well, gives you peace in mind. Use dielectric grease when plugging in to the various relays etc , you’ll not regret!

 

[David99]

Thanks for your replies! Replacing the harness sounds like the way to go. I'd be chasing my tail with all of the splicing that's been done.

 

[JJames]

Thanks for your replies! Replacing the harness sounds like the way to go. I'd be chasing my tail with all of the splicing that's been done.

Aw, where's the fun in that. Lol. Yeah, replacement may be the better solution if it's that bad.

 

[David99]

I still have to run the cost of the harness past my wife. That may be trickier than the rewiring.

 

[JJames]

I still have to run the cost of the harness past my wife. That may be trickier than the rewiring.

"It's cheaper in the long run dear. Did I tell you how cute your hair looks today.

 

[jetmechmarty]

Use dielectric grease when plugging in to the various relays etc , you’ll not regret!

I’m a contrarian when it comes to this subject. Dielectric grease is an insulator. It helps break, not make connections. A little on spark plug boots is fine. If you feel that strongly about waterproofing, replace the connector with a waterproof connector. If you want to put something on the contacts, use Deoxit D5.

 

[Niels B]

I’m a contrarian when it comes to this subject. Dielectric grease is an insulator. It helps break, not make connections. A little on spark plug boots is fine. If you feel that strongly about waterproofing, replace the connector with a waterproof connector. If you want to put something on the contacts, use Deoxit D5.

yes that's correct, it has to be applied correctly to be working, as you state it's an insulator, i use it thinly and plug/unplug several times to make a good metal to metal connection, the excess grease seal the plug connectors. I have been using it for 25 years at east so far without issues. I'll take a look at the Dioxit D5 you mention. new to me but I'm not to old to lear new tricks ;-)

 

[jetmechmarty]

I still have to run the cost of the harness past my wife.

How many pairs of shoes does she have? Or, maybe an expensive habit, like spa days. There has to be something you can use for leverage.

 

[cra-z1]

Give her the choice, you can go to the bar and get nice and drunk, get pulled over and receive a DUI or get the harness. Works every time for me.

 

[Wingedwheel]

It is Father’s Day Sunday. If your not a Dad tell her it’s for your father and he asked for it….

 

[Wingedwheel]

https://www.ebay.com/itm/2571051138...DYqhthT0kdOmVNWqRqy+uW6PD+|tkp:Bk9SR4z72orcZw
I’ve also gone this route before.

 

[Its been a long time]

https://www.ebay.com/itm/257105113861?_skw=1982+yamaha+xs650+wiring+harness&epid=1123323415&itmmeta=01KVGAPQNR7AJ1FZK0JWVJYQNE&hash=item3bdca8b305:g:2AMAAeSwxC5oxKYX&itmprp=enc:AQALAAAA4GfYFPkwiKCW4ZNSs2u11xDYWrV6K7EF1Vt4ZGLPOyCL0slXA/WU7C8drstUb360lCVdMb6w01RfFU6WvnQUOtJ+1ztEF1oNPf6WfZ05MQ4p6mAMMZfSQd5C9lquWINDrnT7f8mtG2+YVlKFLQO+mocG4KxRKSWE3owmfOjoX+VZedisgB1oFuj4Ui7ie1EKhosmW2Toh6zO8tDedSb1/V3LPUrGq1NrW1y90+eUddqhl8zBCFP53SjwIssf96Jfr4UA8onSLL/CihxZbVDYqhthT0kdOmVNWqRqy+uW6PD+|tkp:Bk9SR4z72orcZw
I’ve also gone this route before.

Yes it's amazing when you're talking to your partner telling them what a bargain you got for $10!

 

[Wagner73]

Yes it's amazing when you're talking to your partner telling them what a bargain you got for $10!

It's kind of like the guy (probably all of us!) whose worst nightmare was that, after he died, his wife would sell all of his stuff for what he told her he paid for it!